EP2923820A1 - Procédé de soudage au laser d'un phare de véhicule - Google Patents

Procédé de soudage au laser d'un phare de véhicule Download PDF

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Publication number
EP2923820A1
EP2923820A1 EP15160114.3A EP15160114A EP2923820A1 EP 2923820 A1 EP2923820 A1 EP 2923820A1 EP 15160114 A EP15160114 A EP 15160114A EP 2923820 A1 EP2923820 A1 EP 2923820A1
Authority
EP
European Patent Office
Prior art keywords
light
light guide
lenticular body
laser radiation
automotive
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP15160114.3A
Other languages
German (de)
English (en)
Other versions
EP2923820B1 (fr
Inventor
Cristiano Boero
Domenico Ferigo
Nicola SCHICCHERI
Fabio Leone
Alessandro BUZZURRO
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Marelli Automotive Lighting Italy SpA
Original Assignee
Automotive Lighting Italia SpA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Automotive Lighting Italia SpA filed Critical Automotive Lighting Italia SpA
Priority to PL15160114T priority Critical patent/PL2923820T3/pl
Publication of EP2923820A1 publication Critical patent/EP2923820A1/fr
Application granted granted Critical
Publication of EP2923820B1 publication Critical patent/EP2923820B1/fr
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/20—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/29—Attachment thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1664—Laser beams characterised by the way of heating the interface making use of several radiators
    • B29C65/1667—Laser beams characterised by the way of heating the interface making use of several radiators at the same time, i.e. simultaneous laser welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1687—Laser beams making use of light guides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1687—Laser beams making use of light guides
    • B29C65/169—Laser beams making use of light guides being a part of the joined article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/301—Three-dimensional joints, i.e. the joined area being substantially non-flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/542—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles joining hollow covers or hollow bottoms to open ends of container bodies
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/20—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/29—Attachment thereof
    • F21S41/295—Attachment thereof specially adapted to projection lenses
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S43/00—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights
    • F21S43/20—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by refractors, transparent cover plates, light guides or filters
    • F21S43/27—Attachment thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1664—Laser beams characterised by the way of heating the interface making use of several radiators
    • B29C65/1667—Laser beams characterised by the way of heating the interface making use of several radiators at the same time, i.e. simultaneous laser welding
    • B29C65/167—Laser beams characterised by the way of heating the interface making use of several radiators at the same time, i.e. simultaneous laser welding using laser diodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1674—Laser beams characterised by the way of heating the interface making use of laser diodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2701/00—Use of unspecified macromolecular compounds for preformed parts, e.g. for inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3055—Cars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/747—Lightning equipment

Definitions

  • the present invention relates to a method of laser welding of an automotive light and relative automotive light obtained using said method.
  • automotive light is understood to mean indifferently a rear automotive light or a front automotive light, the latter also known as a headlight.
  • an automotive light is a lighting and/or signalling device of a vehicle comprising at least one external automotive light having a lighting and/or signalling function towards the outside of the vehicle such as for example a sidelight, an indicator light, a brake light, a rear fog light, a reverse light, a dipped beam headlight, a main beam headlight and the like.
  • the automotive light in its simplest form comprises a container body, a lenticular body and at least one light source.
  • the lenticular body is placed so as to close a mouth of the container body so as to form a housing chamber.
  • the light source is arranged inside the housing chamber, which may be directed so as to emit light towards the lenticular body, when powered with electricity.
  • the method of manufacture of an automotive light must provide for the attachment and hermetic sealing of the lenticular body to the container body.
  • Such sealing and attachment is usually performed by welding.
  • the welding may also regard other components of a more complex automotive light, for example arranged inside the housing chamber.
  • a process of laser welding of polymeric bodies particularly of an automotive light makes it possible to combine a transmissive polymeric body, capable of transmitting a laser radiation, and an absorbent polymeric body, capable of absorbing the laser radiation.
  • the laser radiation is transformed into heat when it encounters the absorbent polymeric body which by heating locally transfers heat to the transmissive polymeric body, as far as a softening and a local melting of both polymeric bodies, which thus join firmly to each other.
  • the absorbent polymeric body of an automotive light may be constituted, for example, of a container body, while the transmissive polymeric body of an automotive light may be constituted, for example, by a lenticular body, which closing the container body forms a housing chamber housing a light source of the automotive headlight.
  • the absorbent and transmissive polymeric bodies can be composed generically by further polymeric components of the automotive headlight.
  • the laser welding process of polymeric bodies of an automotive light sometimes has implementation difficulties because of the complex geometry of the polymeric bodies.
  • Surface discontinuities of the transmissive polymeric body such as fittings, ribs, grooves, prominences, curvatures or the like may, for example, obstruct the flow of the laser radiation towards the welding area, which is often distant from an emission point of the laser radiation.
  • a convex-shaped lenticular body may comprise a light guide end capable of channelling the laser radiation emitted by the laser towards the welding area, using at least one reflection of the laser radiation on the inner walls of the lenticular body.
  • experimental tests have shown that the laser emitter and the light guide end of the lenticular body do not cooperate in a very effective manner since only a small portion of the laser radiation emitted by the laser emitter is channelled towards the welding area.
  • the use of a portion of the transmissive lenticular body as a light guide proves to be a poor solution also in the case in which the lenticular body has a discontinuous surface.
  • the laser radiation may be deflected in an uncontrolled manner by the discontinuity, or the correct inclination of the laser radiation with respect to an input area of the lenticular body may be compromised in order to bypass said discontinuity, with consequent waste of laser radiation.
  • the distributor of the laser radiation comprising a light guide formed of flat mirror- treated walls is not able to directly route the laser radiation emerging from an outlet of the laser radiation distributor towards the welding area in some situations, particularly if the lenticular body is a curved shape.
  • the laser radiation distributor may, in fact, sometimes not find any location close to a face of the lenticular body, because it would physically interfere with the lenticular body.
  • the use of the laser radiation distributor comprising mirror-treated, flat walls proves an arguable solution even in the case in which the lenticular body presents a surface discontinuity.
  • a substantial proportion of the laser radiation emerging from the outlet of the laser radiation distributor is deflected in an uncontrolled manner by the surface discontinuity of the lenticular body without reaching the welding area.
  • the lenticular bodies and the container bodies of automotive lights are made of polymeric materials and comprise highly complex geometries with curved or straight coupling surfaces having highly variable inclinations along the entire perimeter of the mutual coupling.
  • Said complex geometry of automotive lights or their components such as the container body and the lenticular body, are ill-adapted to current laser welding techniques which are in fact optimised for applications on flat walls, simple geometries and relatively thin thicknesses of the bodies.
  • a component of the automotive light for example the lenticular body
  • the lenticular body can be crossed by light emitted by the light source so as to realize a light of the automotive light.
  • the lenticular body can assume, therefore, a colouration, which gives the light emitted by the light source the colour required by regulations.
  • a stop light of the automotive light may be realized with a substantially white light source and a lenticular body tending to red.
  • the coloured lenticular body for example tending to red, absorbs a lot of light energy compared to a clear lenticular body during the laser welding process, to the detriment of the light energy provided by the laser source, which must be able to provide a predetermined light energy in the welding area.
  • the purpose of the present invention is to obtain a method of laser welding of an automotive light and an automotive light obtained using said method able to ensure a laser welding process, which makes it possible to reach the welding area with a portion of laser radiation emitted by a bigger laser emitter compared to the prior solutions.
  • the purpose of the invention is therefore to devise a laser welding method of polymeric bodies used in automotive lights able to reduce the power of the laser source compared to that provided by the prior art.
  • the purpose of the present invention is therefore to perform welding of automotive lights by means of a laser welding technique overcoming the technical drawbacks related to the specific nature of automotive lights which to date make this welding technique inconvenient and expensive.
  • Such purpose is achieved by a method of manufacture of an automotive light according to claim 1, and by an automotive light according to claim 22.
  • reference numeral 4 globally denotes an automotive light, which the description which follows refers to without by so doing losing its general application.
  • automotive light is understood to mean indifferently a rear automotive light or a front automotive light, the latter also known as a headlight.
  • the automotive light comprises at least one outer light of the vehicle having a lighting and/or signalling function, such as for example a sidelight, which may be a front, rear or lateral sidelight, an indicator light, a brake light, a rear fog light, a dipped beam headlight, a main beam headlight and the like.
  • a sidelight which may be a front, rear or lateral sidelight, an indicator light, a brake light, a rear fog light, a dipped beam headlight, a main beam headlight and the like.
  • the automotive light 4 comprises a container body 8, usually of polymeric material, which typically permits the attachment of the automotive light 4 to the relative vehicle.
  • the container body 8 may be any shape and size and may even be an element inside the automotive light, for example, not directly associated for example to the bodywork or other fastenings of the associable vehicle.
  • the container body 8 delimits a containment housing 12.
  • the containment housing 12 which houses at least one light source 16, is electrically connected to electric connection means for supplying power to the same, and is adapted to emit a light beam to propagate outside the automotive light 4.
  • the type of light source 16 used is irrelevant; for example, the light source 16 is a light source of light emitting diodes (LED).
  • LED light emitting diodes
  • the container body 8 is delimited by a first perimetral profile 20.
  • a lenticular body 24 in turn delimited by a second perimetral profile 28 is joined to the container body 8.
  • the lenticular body 24 may be either external to the automotive light 4, so as to define at least one outer wall of the automotive light directly subject to the atmosphere; for the purposes of the present invention the lenticular body may also be internal to the automotive light 4, i.e. not directly subject to the external atmosphere and in turn covered directly or indirectly by one or more screens or covering panels.
  • the lenticular body 24 is suitable to close the containment housing 12; according to one embodiment the lenticular body 24 is adapted to transmit to the outside of the automotive light 4 the light beam produced by the light source 16.
  • the lenticular body 24 is made of at least partially transparent or semi-transparent or translucent material, and may also comprise one or more opaque portions, so as to allow in any case the at least partial crossing of the light beam produced by the light source 16.
  • the second perimetral profile 28 is counter-shaped relative to the first perimetral profile 20 so as to be coupled with the latter according to a shaped coupling, in the assembled configuration of the automotive light 4.
  • the assembly of the automotive light 4 comprises the step of joining at least partially to each other the respective first and second perimetral profiles 20, 28.
  • the step is provided for of arranging the lenticular body 24 to close the containment housing 12 of the container body 8 so as to join the respective first and second perimetral profiles 20, 28,
  • the method of manufacture of the automotive light according to the present invention provides for joining the lenticular body and the container body to each other at said perimetral profiles 20, 28, by means of a laser welding.
  • the laser welding process may be realized with different techniques, for example, with simultaneous laser welding, almost-simultaneous laser welding, border laser welding, mask laser welding, radial laser welding, globe laser welding, etc.
  • the laser source 30 which emits a laser beam or a light beam or an electromagnetic radiation having a characteristic emission spectrum.
  • Characteristic emission spectrum is taken to mean an electromagnetic radiation emitted substantially at a certain frequency or having a certain wavelength.
  • the laser source comprises a CO 2 laser, in which the laser beam is produced by a gas mixture comprising CO 2 , or a YAG laser, in which the laser beam is produced by a solid state crystal, or a laser diode (LED).
  • the laser source 30 is associated with an optical fibre 32 inserted in a matrix/guide 33 which has the function of supporting the optical fibre 32 as well as guiding the light beam emitted by the laser source 30, through a distributor 36 of the laser radiation.
  • the welding preferably takes place after blocking the container body 8 in a respective attachment block 35.
  • the container body 8 acts as an absorbing member in relation to the light beam emitted by the laser source and the lenticular body 24 acts as a transmissive member of said light beam.
  • an apparatus for simultaneous laser welding known per se includes an emitter or laser source 30, a bundle of optical fibres 32 and a distributor of the laser radiation 36.
  • the bundle of optical fibres 32 is connected to the laser emitter 30 so as to collect and convey a laser radiation emitted by the laser emitter 30 towards the distributor of the laser radiation 36.
  • the bundle of optical fibres 32 branches off, then, with a plurality of optical fibres 32, each of which terminates with one end, from which a portion of the laser radiation emitted by the laser emitter 30 can be emitted.
  • the ends of the optical fibres are fixed to the support or matrix 33 which is provided with through holes, each of which is able to house and support one end of an optical fibre.
  • the distributor 36 is formed of flat, mirror-treated walls 40, for example two, and is provided with an optical axis X-X.
  • These walls 40 are arranged facing each other, resulting inclined specularly with respect to the optical axis X-X of the distributor so as to define a compartment 42 which starts with an input opening 44 and ends with an output opening 46.
  • the input opening 44 of the compartment 42 is connected to the support 33 for the optical fibres 32, so that the compartment 42 can receive the laser radiation emerging from the optical fibre 32.
  • the outlet opening 46 of the compartment 42 constitutes an output mouth of the laser radiation distributor 36, from which the laser radiation propagated by multiple reflections inside the compartment 42 to the outside of the distributor of the laser radiation 36 comes out.
  • the input opening 44 of the compartment 42 extends with a greater area than that of the output opening 46 of the compartment 42, thus giving the laser radiation distributor 36 a wedge-shaped conformation.
  • This structure of the distributor is responsible for a distribution in portions or lobes Li of the laser radiation at the output 46 of the mouth of the laser radiation distributor 36, as described in the US patent application having the publication number US2006/ 0219675 and briefly referred to in figures 8 and 9 .
  • Portion or lobe is understood to mean a portion of the laser radiation emitted.
  • the zero order lobe L0 is the one having the same direction as the optical axis X-X of the distributor of the laser radiation 36 and is related to a radius of the laser radiation that does not undergo any reflection of the laser radiation inside the distributor 36
  • the lobe of order one L1 is the lobe relative to a radius of the laser radiation emerging from the distributor 36 forming an angle ⁇ with the optical axis of the distributor 36.
  • An additional lobe of order two L2 relates to a radius of the laser radiation which is reflected twice inside the distributor of the laser radiation 36 and forms with the optical axis X-X of the distributor of the laser radiation 36 an angle greater than that relative to the lobe of order one L1.
  • the equipment for simultaneous laser welding referred to previously is used to weld elements particularly of an automotive light 4, such as for example, a lenticular body 24 and a container body 8, to which explicit reference will be made without loss of generality, wherein the lenticular body 24 acts as a transmissive polymeric body, while the container body 8 acts as an absorbent polymeric body.
  • Said lenticular bodies 24 and the container 8 of the automotive light 4 are made, for example, of polymethylmethacrylate, polycarbonate, ABS, and the like, and extend with a complex geometry.
  • the lenticular body 24 may have surface discontinuities.
  • the lenticular body 24, during the welding phase is directly facing the output opening 46 of the distributor of laser radiation 36.
  • the container body 8 delimited by the first perimeter profile 20 is prepared
  • the lenticular body 24 delimited by a second perimetral profile 28 is prepared, associating at least partially with each other the respective first and second perimetral profiles 20, 28 of the container body 8 and of the lenticular body 24, so that the contact surface between said perimetral profiles defines a welding interface 48.
  • At least one laser emission device 30 (for example a light emitting diode or LED) emitting a light beam or radiation having a characteristic emission spectrum is further provided.
  • the emission device 30 is operatively connected to a first light guide 52 or distributor device of the emitted light radiation, said first light guide comprising an input 56 and an output 60 of the light radiation, so as to distribute the radiation from said output 60 according to a spatial distribution comprising a plurality of portions or lobes Li.
  • said first light guide 52 is connected to the support 33 for the optical fibres 32.
  • the method according to the present invention further comprises the step of providing a second light guide 64 or light guide portion inside the lenticular body 24 adapted to obtain a light guide of the light radiation which propagates itself inside the lenticular body 24.
  • Said second light guide 64 of the lenticular body 24 is provided with walls able to satisfy the overall internal reflection condition for at least one portion of the laser radiation defined by the at least one first lobe Li.
  • the first and the second light guides 52,64 are suitably arranged with each other so as to route at least the first lobe or portion Li of the laser radiation coming from the output 60 of the first light guide 52 towards the second light guide 64 of the lenticular body 24, so as to propagate the at least one portion of the laser radiation inside the second light guide 64 towards the welding interface 48.
  • the container body 8 acts as an absorbing member in relation to the light beam and the lenticular body 24 acts as a transmissive member of the light beam.
  • the light beam reaching the welding interface 48 is able to soften and weld together the perimetral profiles 20, 28 respectively of the container body 8 and of the lenticular body 24.
  • the method comprises the step of routing at least one further portion or second lobe L2 of the laser radiation coming from the output 60 of the first light guide 52, towards the second light guide 64 of the lenticular body 24, so as to follow an alternative path as compared to the first portion of the laser radiation relating to the first lobe Li, wherein the second lobe L2 impacts on the welding surface 48.
  • the light beam distributed at the output 60 of the first light guide 52 comprises a plurality of lobes Li, routed towards the second light guide 64 of the lenticular body 24, said lobes having an 'n' level, where 'n' is number of reflections affecting the lobe by passing through the second light guide 64 of the lenticular body 24 before impacting on the welding surface 48.
  • the method comprises the step of manufacturing at least one lobe '0' which impacts on the welding surface 48 passing through the lenticular body 24 without undergoing reflections inside the second light guide 64.
  • the method comprises the step of manufacturing at least two lobes Li of different levels, which impact on the weld interface 48 passing through the lenticular body 24 undergoing a different number of reflections inside the second light guide 64.
  • the first light guide 52 and the second light guide 64 of the lenticular body 24 are aligned in the same direction.
  • the first light guide 52 and the second light guide 64 of the lenticular body 24 are oriented so as to be inclined with each other according to a first and a second direction X-X, Y-Y, in order to bypass surface discontinuities of the lenticular body 24.
  • the first light guide 52 according to the present invention may be realised according to some variants.
  • the first light guide 52 may comprise at least a pair of walls 68 facing each other and mirror-wise inclined relative to an optical axis X-X of the first light guide 52, so as to define a compartment 42 starting with the input 56 and ending with said output 60 for the propagation of the light beam in lobes Li.
  • compartment 42 may be hollow and said walls 68 may be reflective of the light beam incident on them ( figures 15-16 ).
  • the first light guide 52 comprises a solid body suitable to satisfy the overall internal reflection condition for the at least one portion or lobe Li of the laser radiation, the solid body 56 extending from said input to said output 60 ( figures 17-18 ).
  • the first light guide 52 is shaped and placed so as to arrange the output 60 in the proximity of and/or substantially in contact with the lenticular body 24.
  • said output 60 is at least partially counter-shaped relative to the corresponding portion of the lenticular body 24 which it is arranged in proximity and/or substantially in contact with.
  • the mutual orientation between the first light guide 52 and the second light guide 64 of the lenticular body 24 is determined by following backwards the path of a beam of laser radiation belonging to a determined lobe Li of the spatial distribution intended for propagation inside the second light guide 64 of the lenticular body 24.
  • the aforementioned back-tracing procedure can be reiterated to identify possible additional walls of the second light guide 64, separate from said first wall.
  • the back-tracing procedure comprises the step of back-calculating the refraction the beam of laser radiation undergoes when the material from which the lenticular body 64 is made passes through air, so as to identify the direction of the beam of laser radiation coming from the output 60 of the first light guide 52 of the laser radiation.
  • Such direction determines the positioning of the first light guide 52 with regard to the lenticular body 24, for example, placing the axis of the first light guide 52 of the laser radiation with a same direction as that of the beam of laser radiation back-calculated at the output of the second light guide 64.
  • the calculation of the mutual orientation may also provide for the step of estimating a possible deviation affecting the beam of laser radiation due to any surface discontinuity of the lenticular body 24, and/or the step of estimating the overriding of such a discontinuity, again for determining the exact direction of the beam of laser radiation.
  • the laser welding step may be performed by one or more optical fibres 32 which simultaneously emit respective light radiation on separate, predetermined portions of said perimetral profiles 20, 28, according to a 'simultaneous' welding technique.
  • the laser welding process may be realized with different techniques such as for example, with simultaneous laser welding, almost-simultaneous laser welding, border laser welding, mask laser welding, radial laser welding, globe laser welding.
  • the manufacturing method according to the invention makes it possible to overcome the drawbacks of the prior art.
  • the laser welding technique according to the present invention is not only not inconvenient compared to alternative welding techniques of the prior art but may even be better both in terms of cost and time, for the same quality of the welding joint, compared to the solutions of the prior art in the field of automotive lights.
  • the light beam on the interface portion of welding between the lenticular body and the container body is thus suitable to obtain a welded joint having excellent mechanical qualities, without waste of luminous power.
  • the laser welding step regardless of the technique used to perform it, for example of the 'contour' or 'simultaneous' type, is quick and reliable, allowing a further reduction of assembly costs for the same quality of the joint compared to the prior art.
  • At least one lobe of the laser radiation distribution at the output of the mouth of the laser radiation distributor may be able to bypass a possible surface discontinuity of the lenticular body, since it can reach its destination conveyed in the light guide portion of the lenticular body.
  • An automotive light of the invention comprises a container body closed by a lenticular body, so as to form a housing chamber housing a light source adapted to emit light when supplied with electrical energy.
  • the lenticular and container bodies are of polymeric nature.
  • the lenticular body extends with a complex geometry including a portion adapted to act as a light guide for a light radiation, in particular laser.
  • Such automotive headlight is made by the method just described.
  • the present invention is susceptible to numerous embodiments or variants while remaining within the sphere of protection as defined by the appended claims.
  • the laser welding procedure may be implemented with a different technique, for example, with border laser welding.
  • the distributor of the laser radiation may be replaced with a light guide made of polymeric material, such as polymethylmethacrylate, polycarbonate, ABS, or the like, able to receive and propagate within it a laser radiation emitted by a laser emitter.
  • Such light guide has a wedge-shape, so as to impart to the laser radiation in output therefrom a distribution in lobes, wherein at least one of them is intended to penetrate and be propagated inside a light guide portion of the lenticular body to reach the welding area.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Health & Medical Sciences (AREA)
  • Electromagnetism (AREA)
  • Toxicology (AREA)
  • General Engineering & Computer Science (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Laser Beam Processing (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)
EP15160114.3A 2014-03-28 2015-03-20 Procédé de soudage au laser d'un phare de véhicule Active EP2923820B1 (fr)

Priority Applications (1)

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PL15160114T PL2923820T3 (pl) 2014-03-28 2015-03-20 Sposób laserowego spawania lampy samochodowej

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ITPD20140081 2014-03-28

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EP (1) EP2923820B1 (fr)
JP (1) JP6644471B2 (fr)
KR (1) KR102379095B1 (fr)
CN (1) CN104943158B (fr)
ES (1) ES2715876T3 (fr)
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TR (1) TR201904008T4 (fr)

Cited By (6)

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EP2949452A1 (fr) 2014-05-30 2015-12-02 Automotive Lighting Italia S.p.A. A Socio Unico Procédé de soudage au laser d'un phare de véhicule
EP2957418A1 (fr) * 2014-06-19 2015-12-23 Automotive Lighting Italia S.p.A. A Socio Unico Appareil et procédé de soudage laser simultané d'un phare de véhicule
EP3115678A1 (fr) * 2015-06-01 2017-01-11 Automotive Lighting Italia S.p.A. A Socio Unico Procédé de production d'un phare de véhicule et phare de véhicule associé
IT201700041997A1 (it) * 2017-04-14 2018-10-14 Automotive Lighting Italia Spa Attrezzatura di saldatura laser simultanea di un fanale automobilistico e metodo di saldatura laser simultanea di un fanale automobilistico
IT201700114962A1 (it) * 2017-10-12 2019-04-12 Automotive Lighting Italia Spa Attrezzatura di saldatura laser simultanea di un fanale automobilistico e metodo di saldatura laser simultanea di un fanale automobilistico
EP3238920B1 (fr) * 2016-04-27 2022-06-29 Valeo Iluminacion Dispositif lumineux comprenant au moins deux parties soudées au laser

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GB201601974D0 (en) 2016-02-03 2016-03-16 Heraeus Noblelight Ltd Pulsed light system
CN105643099B (zh) * 2016-03-24 2018-11-23 上海信耀电子有限公司 一种车灯焊接装置及工艺
JP6679392B2 (ja) 2016-04-12 2020-04-15 株式会社小糸製作所 樹脂成形品の製造方法及び溶着装置
DE102018105567A1 (de) 2018-03-12 2019-09-12 HELLA GmbH & Co. KGaA Beleuchtungsvorrichtung für ein Kraftfahrzeug sowie Verfahren zu ihrer Herstellung

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US20010028567A1 (en) * 2000-02-29 2001-10-11 Kazuo Akiyama Vehicular lamp unit and method for manufacturing same
JP2001277364A (ja) * 2000-03-30 2001-10-09 Stanley Electric Co Ltd 光エネルギ−による樹脂製部品溶着方法及び光エネルギ−による樹脂製部品溶着装置
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Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2949452B1 (fr) * 2014-05-30 2020-07-01 Marelli Automotive Lighting Italy S.p.A. Procédé de soudage au laser d'un phare de véhicule
EP2949452A1 (fr) 2014-05-30 2015-12-02 Automotive Lighting Italia S.p.A. A Socio Unico Procédé de soudage au laser d'un phare de véhicule
EP2957418A1 (fr) * 2014-06-19 2015-12-23 Automotive Lighting Italia S.p.A. A Socio Unico Appareil et procédé de soudage laser simultané d'un phare de véhicule
US10065363B2 (en) 2014-06-19 2018-09-04 Automotive Lighting Italia S.P.A. A Socio Unico Method of simultaneous laser welding of an automotive light and related automotive light
US10781990B2 (en) 2015-06-01 2020-09-22 Marelli Automotive Lighting Italy S.p.A. Method of making a vehicle light and related vehicle light
EP3115678A1 (fr) * 2015-06-01 2017-01-11 Automotive Lighting Italia S.p.A. A Socio Unico Procédé de production d'un phare de véhicule et phare de véhicule associé
EP3238920B1 (fr) * 2016-04-27 2022-06-29 Valeo Iluminacion Dispositif lumineux comprenant au moins deux parties soudées au laser
EP3388222A1 (fr) * 2017-04-14 2018-10-17 Automotive Lighting Italia S.p.A. Appareil de soudage laser simultané et procédé de soudage laser simultané d'un phare de véhicule
IT201700041997A1 (it) * 2017-04-14 2018-10-14 Automotive Lighting Italia Spa Attrezzatura di saldatura laser simultanea di un fanale automobilistico e metodo di saldatura laser simultanea di un fanale automobilistico
US10940563B2 (en) 2017-04-14 2021-03-09 Marelli Automotive Lighting Italy S.p.A. Simultaneous laser welding apparatus of a vehicle light and simultaneous laser welding method of a vehicle light
IT201700114962A1 (it) * 2017-10-12 2019-04-12 Automotive Lighting Italia Spa Attrezzatura di saldatura laser simultanea di un fanale automobilistico e metodo di saldatura laser simultanea di un fanale automobilistico
EP3470212A1 (fr) * 2017-10-12 2019-04-17 Automotive Lighting Italia S.p.A. Équipement et procédé de soudage laser simultané d'un phare de véhicule
US11331753B2 (en) 2017-10-12 2022-05-17 Marelli Automotive Lighting Italy S.p.A. Simultaneous laser welding equipment of a vehicle light

Also Published As

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CN104943158A (zh) 2015-09-30
KR20150112898A (ko) 2015-10-07
CN104943158B (zh) 2018-10-23
US9874329B2 (en) 2018-01-23
JP6644471B2 (ja) 2020-02-12
JP2015201439A (ja) 2015-11-12
KR102379095B1 (ko) 2022-03-24
EP2923820B1 (fr) 2018-12-19
US20150276159A1 (en) 2015-10-01
TR201904008T4 (tr) 2019-04-22
PL2923820T3 (pl) 2019-07-31
ES2715876T3 (es) 2019-06-06

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